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United Grinding - The Grind Magazine - Spring 2015 Issue


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United Grinding - The Grind Magazine - Spring 2015 Issue - featuring articles regarding CNC Grinding

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United Grinding - The Grind Magazine - Spring 2015 Issue

  1. 1. software + preventive maintenanceFEATURE also in this issue . . . INSPIRING FUTURE ENGINEERS THROUGH COMPETITION page 4 KEEPING PACE IN A FAST-MOVING INDUSTRY page 47 THE UNSUNG HEROES OF ENHANCED PRODUCTIVTY page 3 PREVENTIVE MAINTENANCE Boosts Tool Grinding Productivity, Safety page 6 SOFTWARE FACILITATES Hardware Investments page 12 StuderGRIND Software Optimizes, Documents, and Analyzes All Aspects of Grinding...Offline page 26 page 36
  2. 2. 3 MY THOUGHTS 4 GRINDING IN MOTION 5 CAREER TRACK 24 A GLIMPSE INTO 44 IN THE ZONE 46 DIGITAL DIGEST 47 LAST THOUGHT D E P A R T M E N T S page 18 F E A T U R E S 6 Preventive Maintenance Boosts Tool Grinding Productivity, Safety Tips for maintaining your WALTER and EWAG machines. 12 Software Facilitates Hardware Investments A look into financial software that helps streamline the machine tool purchasing process. 14 Modular Coolant Supply System is Rigid and Reliable Shop Tools introduces the Hirt-Line® articulated modular coolant piping system. 16 Targeting Safety Gains Through Preventive Maintenance Grinding wheel preventive maintenance safety tips from Saint-Gobain. 18 Shop‘s Success Revolves Around Quality and Precision Grinding Shop‘s unique layout puts focus on quality control. 26 StuderGRIND Software Optimizes, Documents, and Analyzes All Aspects of Grinding...Offline Maximizing productivity, cost-efficiency and energy management using grinding machine software. 32 Common Sense Maintenance Optimizes Your Metrology Investment Simple maintenance tips from Marposs to keep running at peak efficiency. 34 Standards-based Data Systems Drive Energy Savings MTConnect provides visibility to factories’ energy choices. 36 Proactive Planning Pays Off Grinding software and OEM support help shop battle back. 42 A Little Grinding Fluid TLC Goes A Long Way Tips on keeping grinding fluids in tip-top condition from Blaser. Grind/Software & PM Issue 2015 1 page6 page 26
  3. 3. 2 Grind/Software & PM Issue 2015 UNITED GRINDING North America 510 Earl Blvd. Miamisburg, OH 45342, USA Tel +1-937-859-1975 Fax +1-937-859-1115 Fredericksburg Branch Office 5160 Lad Land Drive Fredericksburg, VA 22407, USA Tel +1-540-898-3700 Fax +1-540-898-6819 United Grinding Mexico S.A. de C.V. Blvd. Bernardo Quintana No. 7001 Of. 1003 Querétaro, Qro. 76079, Mexico Tel +52-1-555-509-7739 CYLINDRICAL Hans Ueltschi Vice President, Sales 510 Earl Blvd. Miamisburg, OH 45342, USA Tel +1-937-859-1975 Fax +1-937-859-1115 TOOL Markus Stolmar Vice President, Sales 5160 Lad Land Drive Fredericksburg, VA 22407, USA Tel +1-540-898-3700 Fax +1-540-898-6819 SURFACE & PROFILE Larry Marchand Vice President, Sales 510 Earl Blvd. Miamisburg, OH 45342, USA Tel +1-937-859-1975 Fax +1-937-859-1115 CUSTOMER CARE Joseph Szenay Vice President, Customer Care 510 Earl Blvd. Miamisburg, OH 45342, USA Tel +1-937-847-1234 Fax +1-937-859-6915 the GRIND Publisher Ted Neckel Director of Corporate Marketing Tel +1-937-847-1229 Layout & Design dgs Marketing Engineers © 2015. All Rights Reserved. UNITED GRINDING Group International Körber Schleifring Machinery (Shanghai) Co., Ltd. 1128, Tai Shun Road Anting Town Jiading District Shanghai 201814, China Tel +86-21-3958-7333 Fax +86-21-3958-7338 Körber Schleifring Machinery (Shanghai) Co., Ltd. Beijing Branch Office Room 202, Building 18 Tower B, Universal Business Park No.10 Jiuxianqiao Road Chaoyang District Beijing 100015, China Tel +86-10-8526-1040 Fax +86-10-6500-6579 Körber Schleifring Machinery (Shanghai) Co., Ltd. Chongqing Branch Office 15-11 Building 4, No.18 Jinshan Road, Longxi Street, Yubei District, Chongqing 401147, China Tel +86-23-6370-3600 Fax +86-23-6374-1055 Körber Schleifring Machinery (Shanghai) Co., Ltd. Guangzhou Branch Office Room 2003, 20/F Center Plaza Tower B 161 Linhexi Road Tianhe District Guangzhou 510620, China Tel +86-20-3862-1241 Fax +86-20-3862-1270 United Grinding GmbH India Branch Office No. 487 - D1 & D2A 4th Phase, KIADB Main Road Peenya Industrial Area Bangalore 560058, India Tel +91-80-415-54-601 Fax +91-80-415-54-603 United Grinding GmbH Moscow Office 1-j Kasatschij Pereulok 5/2, Strojenije 1 119017 Moskau, Russia Tel +7-495-956-93-58 Fax +7-495-956-93-59 Grind/Software & PM Issue 2015 3 The Unsung Heroes OF ENHANCED PRODUCTIVITY M Y T H O U G H T S Terry Derrico President and CEO, United Grinding North America, Inc. “Software allows our grinding machines to handle diverse customer profiles— from individual component to large-batch production.” Manufacturers today are always looking for ways to accelerate production cycles and reduce machine downtime. In this issue of The Grind, we highlight a couple of unsung heroes – software and preventive maintenance – that quietly enhance productivity by making life easier for operators and keeping machines up and running. At UNITED GRINDING North America, we have a long history of providing high-precision, high-output grinding solutions that encompass both machine and software technologies. It is this fact that separates us from our competitors. Software allows our grinding machines to handle diverse customer profiles — from individual component to large-batch production. It’s ultimately what makes grinding easier. Our outstanding team of developers has designed unique software for a variety of applications. In fact, in this issue, you’ll read about AcuTwist, a small shop in Pennsylvania that attributes much of its growth and success to the use of our HELITRONIC TOOL STUDIO CAD/CAM software. This cutting tool company has grown from one machine in the owner’s garage into a successful business with several employees using multiple WALTER grinding machines to design, program and produce all types of specialty tools. Throughout this issue, you’ll also find information on the importance of performing routine, preventive maintenance. Each year, our service team makes significantly more service calls to shops that don’t properly maintain their machines compared with those that do. To help customers with this important aspect of their business, we offer on-site preventive maintenance programs. In fact, we’re seeing increased demand for these types of services and have plans to expand our offerings in the near future. I hope you enjoy this issue of The Grind. At UNITED GRINDING North America, we are committed to providing you with information that will help you grow your business and bottom line. If you have ideas for topics you’d like to see covered in our magazine or have a story to tell about how our grinding technology has helped you grow your business, we’d love to hear from you.
  4. 4. 4 Grind/Software & PM Issue 2015 Grind/Software & PM Issue 2015 5 UNITED GRINDING North America is always looking forward and wants to ensure the future is filled with talented manufacturers and engineers. The company has discovered that one sure way to entice the best and brightest to seek careers in science, technology, engineering and math is to get involved with them early. For a second consecutive year, UNITED GRINDING North America sponsored the Musket Alliance, a robotics team comprised of students from two rival high schools in East Tennessee, for the FIRST™ Robotics Competition. This CAREER TRACK Customer Support Inspiring Future Engineers T H R O U G H C O M P E T I T I O N And because most colleges require their engineering students to participate in co-ops, UNITED GRINDING plans to participate in one to ensure its future customer support team is fully staffed with trained, well-educated individuals. The company also conducts extensive candidate searches within various associations (veterans and others) and encourages those with transferrable skills resulting from extensive experience in industry-related positions to consider being part of the customer support team at UNITED GRINDING. Current Customer Support openings at UNITED GRINDING: • Applications Engineer, Cylindrical Products Group (Miamisburg, Ohio) • Field Service Engineer, Cylindrical Products Group (Chicago, Elgin, Rockford, Milwaukee area) • Sales Engineer, Spare Parts Sales (Miamisburg, Ohio) • Field Service Engineer, Tool Products Group EWAG (Chicago, Elgin, Rockford, Milwaukee area) • Automation Sales Engineer, Surface and Profile Products Group (Miamisburg, Ohio) • Regional Sales Manager, Tool Products Group (California) To apply, please email your resume to: Business for UNITED GRINDING continues to grow, and with it comes the immediate need to expand the company’s customer support teams — in particular applications engineers and field service engineers. At UNITED GRINDING, service and support are as equally critical to a customer’s success as the advanced software and grinding technology the company provides. Employee turnover at UNITED GRINDING is extremely low — typically less than six percent. “This consistently low rate is because, once on board, individuals realize that UNITED GRINDING is an amazingly rewarding and exciting place to work,” explained Christine Taylor SHRM-SCP, SPHR, director of corporate human resources at United Grinding North America, Inc. “Most job openings here result from those individuals that have advanced to other positions within the company.” UNITED GRINDING applications engineers ensure today’s manufacturers get the right technology for their specific production needs, while field service engineers keep that technology operating at its full potential. The current applications and service openings are challenging jobs, and candidates must possess specific sets of skills and experience. The positions also require a fair amount of travel. For those individuals with the basic electrical and mechanical concepts and education, UNITED GRINDING will train them on its various technologies, further advancing the knowledge and capabilities of those individuals. In fact, UNITED GRINDING has added new training programs and initiated application and service engineer recruiting efforts at the college level. unique team brings together students from David Crockett High School, which has a strong vocational program, and Daniel Boone High School, which excels at computer programming, to capitalize on the strengths of each school. The FIRST Robotics Competition is an international high school competition in which teams have six weeks to build a game-playing robot. The game changes each year to keep the competition fresh and on a level playing field. This year’s game, which kicked off on January 3, took on a recycling theme. After picking up the competition manual and a standard set of parts to build their robots, the Musket Alliance divided its 20 members into five teams — electrical, CAD design and animation, programming, mechanical and business — and got to work. Each team managed its assigned aspect of the robot build, including purchasing additional parts and materials to make specialized parts. The business team secured sponsors and handled the logistics for team travel and robot transport. At the Palmetto regional competition in Myrtle Beach, South Carolina on February 25-28, the Musket Alliance robot competed on a playing field that was 26 feet by 27 feet. During one period, the robots were required to operate independently of their drivers to move yellow totes and recycling containers into a specified area. Then, student drivers remotely controlled their robots and worked with other teams to earn points by placing as many totes on their scoring platforms as possible and capping those stacks with recycling containers. The robots also had to properly dispose of pool noodles, representing litter. At the end of the weekend, the Musket Alliance finished 15th out of 66 teams. “Participating in this competition was an incredible experience for these students, but it came with a significant price tag,” explained Bob Beals, applications engineer for United Grinding North America, Inc., whose son, Sawyer is a sophomore at David Crockett High School and a member of the Musket Alliance. “The students from both of these schools appreciate UNITED GRINDING for giving them an opportunity to develop technical, business and teamwork skills, and make new friends.” Ted Neckel, director of corporate marketing for United Grinding North America, Inc., reiterated the company’s commitment to developing the future leaders in the engineering field. “This is a great program that fosters engineering and technology skills in young people, and inspires them through an exciting competition. This is not only important to the future success of UNITED GRINDING North America, but to the success of our industry as a whole.”
  5. 5. 6 Grind/Software & PM Issue 2015 Grind/Software & PM Issue 2015 7 Wheel Mounting Issues To ensure consistent part accuracy, grinding wheel adapters require periodic checking and replacement. The excellent rigidity, runout, and repeatability of WALTER HELITRONIC POWER machines result in part from the machines’ unique compression-fit wheel adapters. A compression-fit adapter features simultaneous contact on both the taper and the flat end face. That rigid contact relies on tight tolerances of both the adapter and the spindle nose geometry. Wear of the mating surfaces results from repetitive elastic deformation of the semi-hardened steel adapter
over the hardened steel spindle nose. In addition, normal handling of an adapter often causes nicks and other damage. Wear or nicks may limit mating to only one surface, creating instability that reduces spindle life, lowers grinding feedrates, decreases wheel life, and produces inferior grinding finishes. Consequently, it is essential to check adapters at least quarterly. The best inspection method involves applying machinists’ blue layout fluid to the machine’s spindle taper and face, then mounting a wheel adapter. Upon release, the adapter should indicate contact
on the front 30 percent of the taper nose and show a full ring on the flat face. If contact shows on more than 30 percent of the short taper nose, or if contact on the flat face is incomplete, the adapter is excessively worn. The loss of rigidity in the worn connection may result in vibration and poor machining results. The adapter should be discarded and replaced. Another wheel-mount maintenance issue involves the HSK wheel adapters on WALTER HELITRONIC VISION and HELITRONIC DIAMOND machines. It is important to accurately torque these adapters; using too little torque will fail to secure the wheel, while too much torque will damage the screw or the adapter. In mounting an HSK wheel adapter, the small hole in the adapter is aligned with the red mark on the spindle end and a torque wrench is used to tighten the hex screw to 124 pound-inches (14 Newton-meters) torque. It is important to not confuse the VISION/DIAMOND HSK wheel adapters with the WALTER taper fit adapters used on the HELITRONIC POWER series (POWER R, POWER PRODUCTION, POWER DIAMOND, MINI POWER, etc.). HELITRONIC POWER adapters use a different mounting method and torque setting. Air Quality Matters An often-overlooked maintenance issue is the quality of the compressed air supplied for the machine’s clamping systems, pneumatic valves and air purges. The air must be clean and dry. Machines typically have air separators to remove excess moisture, but they are designed to work with air that meets ISO8573-1 specifications, namely Class 3 for oil aerosols, Class 5 for particulates and Class 4 for vapor pressure dew point. Air quality is crucial for dependable operation of key machine systems. For example, the WALTER HELITRONIC POWER PRODUCTION machine has air purges in the grinding spindle and glass scales and uses air to operate the spindle lock, tool clamping cylinder, coolant valve pneumatics and loader pneumatics. Contaminated air eventually causes malfunctions in these components, such as sticking valves or, in the case of glass scales, inaccurate positioning of the axes. Software Safety Manufacturing software has become a make-or-break component of the machining process. When functioning as intended, software can facilitate unmatched productivity; corrupted or otherwise defective software can totally shut down an operation. Protecting machine software from contamination by corrupted data and viruses is crucial. Some problems are simply the result of misguided good intentions. For example, the popularity of familiar PC-based operating systems gives many users the confidence to make software changes independent of input from the machine or control manufacturer. However, software modifications made without specific instructions from UNITED GRINDING will void the machine warranty and could cause serious machine damage or operator injury due to uncontrolled machine motions. anufacturing machinery requires regular maintenance to achieve maximum productivity, accuracy and reliability. It also is necessary to maintain and protect the software systems that are crucial in the operation of modern machine tools. Safety requirements must be met as well. Accordingly, UNITED GRINDING offers the following tips for effective preventive maintenance procedures. Preventive Maintenance BOOSTS TOOL GRINDING PRODUCTIVITY, SAFETY “To ensure consistent part accuracy, grinding adapters require periodic checking and replacement.” F E A T U R E
  6. 6. 8 Grind/Software & PM Issue 2015 Grind/Software & PM Issue 2015 9 In general, users should not install software without guidance from UNITED GRINDING. This includes anti-virus software (see the next entry in this maintenance tips list), automatic backup/restore software or video games. Users should not install a network without consulting with UNITED GRINDING, nor should they move files with Windows® Explorer or perform any administrator functions in the machine’s operating system. Making changes in PC software may seem simple, but independently altering a machine operating system is not worth the risk of damaging the machine or worse. Going Anti-Viral A key tactic in avoiding corruption of machine operating software is keeping it isolated from sources of computer viruses. Networking and file sharing provide tremendous assistance in improving productivity, but they also introduce the risk of spreading viruses. Viruses may degrade machine performance and even lead to data loss. To protect machines from computer viruses and limit the damage if infected, the latest anti-virus software should be installed on all PCs that are connected to the Internet. Going a step further to install anti-virus software on every PC in the facility, whether connected to the Internet or not, significantly reduces the risk of potential contamination via shared media. For the same reason, a virus-free PC should be used to scan all portable media (memory sticks, CDs, etc.) before connecting the media to a machine. Virus-free machine files should be backed up regularly. Machine tools should not be connected to the Internet except to obtain remote teleservice from UNITED GRINDING. It is important to note that taking the above precautions generally makes it unnecessary to install anti-virus software on machine tools; such software is not recommended because it may negatively affect machine performance. Maintaining Backup Power Backup batteries are just that: a temporary safety net in the event of main power failure. The batteries should not be used to cover extended, anticipated outages such as holidays or plant shutdowns. Batteries should be changed every year even if their expected life is longer because unanticipated circumstances can shorten battery life. Machine downtime is much more costly than replacing batteries. Some machines and components have special requirements or characteristics regarding backup power. For example, Programmable Logic Controls (PLCs) use a battery for power when the machine is turned off. The battery protects the memory from losing the PLC program that controls limit switches, motors, valves and much more. 
 The uninterrupted power supply (UPS) in some WALTER HELITRONIC POWER machines uses a battery to provide enough electricity for a graceful control shutdown when the external power source fails. The UPS does not, however, “The new manifold and nozzles al- lowed us to switch from plated to brazed CBN wheels. The higher pro- ductivity and wheel life saves us $2.7 million per year.” Orthopedic implant manufacturer “The new nozzles reduced flow rate by 33% and dropped the part temperature by 40°F. Wheel life between dressing doubled.” Automotive camshaft manufacturer “Spending $1,000 on your nozzles saved us $100,000 a year!” Aerospace bearing manufacturer Trying is BELIEVING. Try a Cool- Grind nozzle at no risk now. Visit COOL-GRIND.COM or call (860) 429-8822 provide enough electricity to run the machine. (Most “UPS failures” are simply battery failures.) 
 Battery power loss on a FANUC machine will require re-measurement of the machine axes and resetting of the zero points. That is a four-hour job, assuming a shop is capable of doing it; if not, the expense of battery failure will include that of a service visit. It is crucial to maintain power to the machine while changing the battery, and to replace both PC and CNC batteries at the same time. Proper Shutdown Procedures In an issue related to machine power status, WALTER HELITRONIC machines with the HMC 600 or FANUC control run the Windows operating system and do not have a UPS. With these, and all Windows-based operating systems, it is critical to follow proper shutdown procedures. Shutting down the machine at the main disconnect, without first shutting down Windows, can corrupt the operating system and The shutdown procedure is somewhat different for FANUC and Andron (HMC) machines.
  7. 7. convenience. Regularly scheduled preventive maintenance ensures a proactive approach to machine performance and production, maximizes machine uptime and provides organized maintenance records. Careful attention to machine tool mechanical, software and safety issues will pay multiple benefits in terms of the productivity, responsiveness and, ultimately, the profitability of any manufacturing operation. Learn more 10 Grind/Software & PM Issue 2015 Grind/Software & PM Issue 2015 11 could damage the hard drive. Years of tool development can be lost as well if the data has not been backed up regularly. The operator must wait until the appropriate Windows shutdown screen appears before turning off the power to any machine running the Windows operating system. This applies to HELITRONIC machines with the HMC 500, HMC 600, or FANUC control, HELICHECK and HELI TOOLCHECK machines, and most EWAG CNC machines. The shutdown procedure is somewhat different for FANUC and Andron (HMC) machines. When shutting down a FANUC machine, the operator should click the WWM icon at the bottom of the Windows shutdown screen and select “Close all Windows” then select “Shut Down” when the option appears. When another window opens, the operator should select “Shut Down” (never “Restart”) then
“OK.” The screen will read “Windows is Shutting Down.” When the screen displays “It is now safe to turn off your computer,” the main disconnect can be shut off. 
 On the other hand, when shutting down an Andron (HMC) machine, the operator should press the “Windows Key” to open the Windows start up icons and select “CLOSE WINDOWS.” When the option appears, the operator should select “Shut Down.” Then, when another window opens, the operator should select “Shut Down” (never “Restart”) then “OK.” The main disconnect can be shut off when the screen reads “No Signal.” 
 Safety First: Fire Extinguishing Systems Whenever oil coolant, dielectric or similar machining fluids are in use, there is risk of fire. Many state and local regulations require a fire extinguisher system anywhere oil coolant is in use. The system must be charged and inspected onsite prior to startup and re-inspected and certified on a regular basis as required by law. To help shops fulfill these responsibilities, UNITED GRINDING can provide the name of a local fire extinguishing system supplier or make arrangements for installation by a company technician. UNITED GRINDING can also name potential local suppliers to service existing systems. Door Lock Safety All machine tools today have automatic safety locks to prevent the door from being opened during operation. Some shops operate machines with disabled lock safety switch circuits, but this presents a serious safety hazard. It also should be noted that, like door locks, the Axis Enable Foot Switch should never be disabled. Periodic Preventive Maintenance UNITED GRINDING has developed scheduled preventive maintenance programs to periodically inspect machines and identify potential problems before they occur. The company checks items such as belt tension, lube fluids and filters and machine geometry, and reports in detail what components need attention. Scheduled preventive maintenance as a planned expense will reduce or eliminate the cost of unexpected service calls, while reinforcing productivity. Machines can run continuously when needed, and downtime can be scheduled at the shop’s PRECISION SPEED POWER Grinding Spindle repair and service on all makes and models. Grinding Arbor and accessory sales. Quality and Expertise that only an OEM spindle manufacturer can provide. Over 75 years of excellence at your service. Contact us today to start your FISCHER experience. FISCHER USA, Inc. | Racine WI | | | T 800 333 6173 | F 262 632 6730 O O O O O *Grinding wheel not included When the coolant becomes a Liquid Tool. Blaser Swisslube AG 3415 Hasle-Rüegsau, Switzerland Phone +41 34 460 01 01 «The right product – correctly applied, and I guarantee a higher feed rate.» Rico Pollak Head of Grinding Technology
  8. 8. 12 Grind/Software & PM Issue 2015 Grind/Software & PM Issue 2015 13 United Grinding North America, Inc. recently named National Machine Tool Financial Corporation (NMTFC) as a financial service provider. A First Midwest Bank Company, NMTFC offers a wide variety of financial software programs that guide shops in the selection and financing of machines that will provide maximum investment returns as well as improved part-making productivity. Basic financial software includes tools called ROI calculators. With one type of ROI calculator, users enter information into an Excel® -format spreadsheet to compare the financial benefits of a potential new machine versus their existing machine and process. Another ROI calculator permits comparisons of a variety of possible new machines and processes. The calculator projects the additional profits generated and estimated payback time of the investment in new equipment. Often, these calculations point out that a lower selling price does not necessarily lead to quicker payback, increased profits or higher satisfaction. Machine tool manufacturers and distributor sales teams themselves use ROI calculations to justify the solutions they suggest to potential customers. A monthly payment calculator is another widely used financial software tool. Users enter the amount to be financed, the length of the loan and the finance rate, and the software calculates the monthly payments. Payments can be broken down further into cost per hour for 1, 2 and 3 shift operation. Although these data do not fully represent the total cost of machine ownership and operation, they provide a reliable indicator of the fundamental costs of owning the machine and accessories that will produce the work in the most profitable way. A tax savings calculator previews the potential savings associated with tax code options such Section 179 and Bonus Depreciation. The machine buyer enters the price of the equipment, and the financial software quickly determines possible tax benefits under the current tax code. NMTFC updates the calculator to reflect yearly changes in the code, and the calculator is provided in an Excel format so it can be stored on a computer for quick accessibility. While not considered to be a formal interpretation of tax law, the calculations provide basic information that can be useful in consulting with an accountant or other tax professional to confirm eligibility for tax incentives and benefits. In the credit evaluation process, NMTFC utilizes an in-house “spread software” to quickly calculate many of the factors that go into financing approval. The information involved includes the customer’s trends in revenues and costs, company liquidity, cash flow, debt to tangible net worth ratios and EBITDA (earnings before interest, taxes, depreciation and amortization). The software completes the analysis in minutes. This information helps NMTFC understand the customer’s financial ability to handle the payments and makes the approval process easier and quicker. Once the information is analyzed, it allows NMTFC to function as a consultant to the customer, and help in the decision process if needed. Since 1986, NMTFC has provided financing solutions that have helped thousands of companies obtain the equipment and financing arrangement that suits them best. Many solutions are creatively structured to accommodate specific customers equipment needs and financial situations. As partners with United Grinding North America, Inc. to provide financing solutions, the role of NMTFC is simple: to make the purchase of the UNITED GRINDING equipment easier for its customers. With benefits parallel to those of manufacturing software, the financial software available through NMTFC can help justify the purchase of the equipment that will produce high quality parts faster and more consistently, while at the same time optimizing operational efficiency and uptime. And, as with manufacturing software, the results are maximum profits, steady cash flow, and strong business growth. Learn more anufacturing software enables machine tools to produce high-quality parts quickly and consistently while optimizing operational efficiency and uptime, resulting in increased profits, steady cash flow and strong business growth. Similarly, financial software provides a variety of benefits in the machine tool purchasing process. Use of financial software can help a business justify and manage the significant investment required for a machine tool. Software packages have been developed to determine what is affordable, what type of financing is optimal and whether it is best to pay cash or let the machine generate the revenues for machine payments. Scott Brossard, CMTSE, National Machine Tool Financial Corporation F E A T U R E Software Facilitates “The financial software available through NMTFC can help justify the purchase of the equipment that will produce high-quality parts faster and more consistently, while at the same time optimizing operational efficiency and uptime.” Hardware Investments
  9. 9. 14 Grind/Software & PM Issue 2015 Grind/Software & PM Issue 2015 15 NITED GRINDING provides state-of-the-art machines that maximize grinding productivity and efficiency. The company recognizes that its machines achieve top performance when complemented by equally advanced ancillary systems and accessories. Among the critical elements of the grinding process are coolant supply systems. Sufficient, consistent and accurate coolant delivery prevents heat-related damage to the workpiece and grinding wheel as well as flushes away swarf and provides lubricity. Interruption or misdirection of coolant flow can severely compromise workpiece surface finish and wheel life. A coolant system’s final delivery components can be a source of supply problems. Plastic coolant piping and nozzles or light metal tubing may shift out of position due to the pressure of the coolant flow itself. Corrosion, heat and abrasion may also affect the tubing arrangement. Tubing elements can kink or break. As a result, UNITED GRINDING now offers an articulated modular coolant piping system for its STUDER cylindrical grinders that provides unfailing rigidity when assembled but can easily be custom-configured to match any grinding application. The Swiss-made Hirt-Line® coolant delivery system consists of a series of threaded stainless-steel elements that screw and lock together and extend from the machine’s coolant source to the nozzle that ultimately directs coolant flow. The U.S. importer of the Hirt-Line system is Shop Tools, Inc., Colorado’s largest independent distributor. Shop Tools introduced the Hirt-Line system at IMTS 2014, after which UNITED GRINDING began to offer the system to its customers. Shop Tools representative Tim Young said, “Coolant is one of the most important things in a shop, but people consider it a necessary evil. Just because the coolant is on doesn’t mean it is helping. It has to be in the right spot.” The Hirt-Line system comes in 5.8-mm and 11-mm I.D. sizes. Basic components consist of machine connection adapters with a choice of thread configurations; screw-together pipe elements in lengths ranging from 21 mm to 1,000 mm; ball connectors to create curved piping; a variety of movable and fixed elbows F E A T U R E “Coolant is one of the most important things in a shop, but people consider it a necessary evil. Just because the coolant is on doesn’t mean it is helping. It has to be in the right spot.” including angle, star, T and Y choices; and a wide selection of round and flat nozzles. The system also features accessories such as ball valves, plugs and manifold blocks. The pipe elements have wrench flats that permit them to be locked together and resist movement against coolant pressures as high as 1,500 psi. Components can be configured to produce 180-degree curves if desired, and will not kink or break. Their tough 303 stainless steel composition provides high resistance to impact, corrosion and wear. Hirt-Line continually develops new components for the system and also has the capability to produce special designs for particularly challenging applications. Users can tailor coolant flow to the exact part locations and wheel widths involved, in many cases positively affecting grinding wheel and dressing tool life. In the past, custom-fabricated nozzles and tubing arrangements have worked well in some applications. However, production downtime and increased expense resulted when a nozzle broke or wore out and needed to be remade. The modular nature of the Hirt-Line system enables it to be configured for nearly any application, but also guarantees the availability of parts for quick, cost-effective replacement or modification for new applications. The Hirt-Line system has proved to be excellent for use in high-volume manufacturing where machines are dedicated to longer-term production of a single part or a family of similar parts, situations where changeover is minimal and reliable performance is a top priority. Currently, typical users are Tier 1 and 2 suppliers in the automotive and aerospace industries that are employing the system on STUDER S41 and S33 machines in multi-shift grinding of similar parts using high-pressure coolant. Young said the extensive selection of elements allows assembly of a nearly infinite number of setup combinations. “You can plumb coolant and get it where you need to have it. You are only limited by your imagination,” he said, “It’s kind of like an Erector Set for big boys.” Learn more ModularCoolantSupply System is Rigid and Reliable
  10. 10. Heavy Wheels Support on clean hard floor. Light Wheels Suspend from hole by small pin or finger. FLOOR “TAP” HERE 45º 45º 45º 45º C C 45º 45º 16 Grind/Software & PM Issue 2015 Grind/Software & PM Issue 2015 17 1. Maintenance of the Grinding Wheel Ordinarily, one does not think of grinding wheels in terms of maintenance. First, they are consumable products, and second, they have no moving parts. But, because grinding wheels often have a lifespan of up to several years, it is important to know how to maintain them properly. That grinding machines come with safety guards is not coincidental. Consider that most precision grinding wheels operate at speeds of around 100 mph or 45 m/s. The energy inside a spinning grinding wheel is extremely powerful, and if a grinding wheel breaks while in motion, that energy is released in a split second with potentially catastrophic results. One of the most important PM considerations with respect to the grinding process is the inspection of the grinding wheel. Damage to the wheel can weaken it significantly, making it susceptible to breakage during use. The following two inspection steps should always be taken prior to using a wheel, even if it has been mounted and used before. The Ring Test This simple test applies to most precision abrasive wheels. To perform this test, hang the wheel from the index finger (heavy wheels can be stood vertically on the floor) and tap it with a hard, non-metallic object in the upper-right and upper-left quadrants. An undamaged wheel will emit a clear ringing sound, but a cracked wheel will produce a ‘thud.’ Then, rotate the wheel 45 degrees and repeat the process until all quadrants have been inspected. The One-Minute Free Spin Test Prior to grinding with a newly mounted wheel, bring the grinding wheel up to operating speed and allow it to run for one full minute before grinding. During that time, be sure that no one stands within the wheel’s plane of rotation. If the wheel is critically damaged, this test will cause it to fail in a controlled environment. Implementing these two simple tests as regular PM inspections will reduce the likelihood of a wheel breakage and thus enhance the safety of the grinding process. While inspecting the wheel is an important preventive safety measure, it is not necessarily a proactive one. Proactive safety with abrasive products is accomplished through proper use, which includes but is not limited to storage, handling, mounting, guarding, balancing, dressing, cooling and grinding. A safe and robust grinding operation employs regular checks and redundant safeguards to ensure that wheels are correctly used and maintained. (For details about these aspects of grinding wheel use, please refer to ANSI B7.1-2010 or 2. Maintenance of the Mounting Flanges Throughout the world, Saint-Gobain is perhaps best known as a producer of glass. Our glass is featured in many famous structures, including the Grand Canyon Skywalk, a U-shaped bridge that overhangs the edge of the Grand Canyon by 70 feet. The glass floor panels afford tourists an incredible view of the river below. While glass can safely support the weight of the tourists, the designers wisely selected steel over glass to support the entire one-million-pound structure. Why? Glass is strong but brittle, and this brittle composition makes it very sensitive to concentrated loads. Vitrified grinding wheels are made of glass; therefore, they are also strong yet brittle. As a result, concentrated forces can cause the wheels to break, which could lead to disastrous consequences. The condition of flanges (i.e. wheel mounting equipment) is of critical importance because irregularities in the bearing surface will magnify stresses on the wheel. Combined with the normal stresses of rotation and grinding, these additional mounting stresses can cause the wheel to crack and eventually break. When it comes to mounting, good equipment must be coupled with good procedures. Even pristine flanges can cause problems if clamped down excessively. Please reference the aforementioned national safety standard, ANSI B7.1-2010, for complete design and condition requirements for mounting flanges. In closing, the application of sound preventive maintenance principles to grinding wheels and equipment bolsters the overall safety of a grinding process. Through the inspection of wheels, equipment and operating procedures, potential hazards are avoided and processes can run productively and safely. Learn more reventive Maintenance (PM) is essential to sustaining long-term product quality. Regular and thorough PM routines keep machines churning out good parts at target rates with minimal unplanned downtime. In addition to product quality, workplace safety also improves as a result of effective preventive maintenance, because when machines function according to their intended design, fewer hazards exist. But even greater safety gains are achieved by intentionally incorporating safety checks into PM activities. The following addresses two important preventive maintenance components that contribute greatly to safety in the context of the grinding process. Ethan Weikleenget, Senior Product Safety Engineer, Saint-Gobain Abrasives, Worcester, MA F E A T U R E Targeting Safety Gains Through Preventive Maintenance THERINGTEST
  11. 11. 18 Grind/Software & PM Issue 2015 Grind/Software & PM Issue 2015 19 ommer Tool & Mfg., Inc., a leading North American manufacturer of custom mold-ready components, follows a unique formula when it comes to precision and quality. Everything in the company’s 24,000 square-foot facility in Arlington Heights, Illinois, literally revolves around part quality, with the shop floor laid out in a hub-and-spoke plan that puts quality control in the center of its 11 machining departments. This strategy, along with a transition from manual to automatic O.D. grinding, has catapulted Hommer to performance excellence, helping the company succeed in delivering perfect parts and impeccable service. When creating molds for small parts, injection moldmakers depend on the highest quality components. For some Shop’s unique layout puts focus on quality control. F E A T U R E Shop‘sSuccess RevolvesAround Qualityand PrecisionGrinding Precision tolerances as close as 0.0002" are the norm because quality is at the heart of everything Hommer does.
  12. 12. 20 Grind/Software & PM Issue 2015 Grind/Software & PM Issue 2015 21 Hommer creates precision components out of all types of materials, including S7, H13, D2, M2 420, copper and MoldMAX® . The company chose STUDER because the programming is superior and consistent across all machines. Highly skilled employees are capable of programming, setting up and operating the machines. O.D. grinding at the time was basic, the company was limited to manufacturing simpler pieces that were 1" or less in diameter and 12" or less in length. “As a growth strategy and strategic plan, my first major move was to hire a marketing manager,” explained Hommer. “Then, out of the blue, I received a promotional mailer from a manufacturer of automated grinding machines, which put that kind of machine on my radar.” After researching the options available from the various manufacturers of grinding solutions, Hommer honed in on UNITED GRINDING’s STUDER cylindrical grinders. The shop now has several STUDER machines, the recent ones being an S40 and an S33. As a most significant benefit to Hommer, the S33’s turret wheelhead features two O.D.-wheel spindles and provides one-degree increment automatic-indexing capability when needed for the shop’s complex parts. The highly versatile S33 with measuring functionality sports a center height of 6.9" and distance between centers of 25.6", with a maximum workpiece weight between centers of 176 lbs. industries, such as medical device or pharmaceutical, precision is everything. But as any moldmaker will attest, it doesn’t happen by accident. Instead, precision tolerances result from a commitment to quality and high-performance grinding technology. At Hommer, precision tolerances as close as 0.0002" total tolerance are the norm because quality is at the heart of everything they do. Every workstation in the spotlessly clean, temperature-controlled shop is equipped with tenth-indicating micrometers and high-accuracy drop indicators. A barcode tracking system maintains complete traceability for each and every process. The company only hires the most highly-skilled people capable of programming, setting up and operating the machines, and has a detailed process for cultivating those skills in-house. When James “JR” Hommer Jr. stepped into a leadership role and assumed complete responsibility of the business about 15 years ago, he quickly saw that customer needs were changing. At the time, Hommer’s business model was to manufacture simpler round components for the injection molding market, but customers were beginning to ask for more complex parts. Because their CNC
  13. 13. operate them,” said Hommer. “It would be very difficult for a shop to invest in all of this equipment at once.” Another key to Hommer’s success is the understanding that the company can’t run its operations by exception. Rick Frankowitch, operations manager at Hommer, explained that customers hold Hommer to an extremely high standard and don’t want any variability in the tool. After all, these customers need to be able to guarantee millions of parts for their molds, so Hommer can’t deviate when it comes to quality. “We can’t tell employees that one customer’s part has to be perfect, but another customer’s doesn’t,” shared Frankowitch. “When our clients need perfect component parts, they turn to us because they know we’ll give them the perfect component that can deliver every single time.” While Hommer is often more expensive than the competition, customers are willing to pay the higher price point because the company consistently produces parts that are true to the print specifications. Each step of the company’s production process involves precision tolerances, exacting workmanship and rigorous quality control systems that begin with the first piece and span the entire process to final inspection. Clearly the commitment to quality pays off. “I had a customer pay our company the ultimate compliment,” Frankowitch said with a smile, “he said he wastes a lot of time checking perfect parts.” Learn more 22 Grind/Software & PM Issue 2015 Grind/Software & PM Issue 2015 23 Hommer admits, however, that he doesn’t make the purchases lightly. “The capital investment for a STUDER is significant, so I do a lot of due diligence before making the decision,” he said. To illustrate, he shared that prior to acquiring the shop’s second S40, Hommer completed a scheduling project that analyzed each facet of the business. The results clearly identified O.D. grinding as a capacity constraint, so the company changed some scheduling processes and evaluated its machining capabilities. In doing so, the staff recognized that one of the STUDERs, an S33 with a fixed head, was not helping the company keep up with the growing demand for more complex parts. The machine did straight O.D.s, but could not achieve features such as angles, longitudinal positioning multiple diameters or out-of-round grinding. Hommer replaced it with the S40, which took the O.D. grinding department from a capacity of 150 to 250 hours per week. This move right-sized Hommer for the workload at the time, but offered no room for growth. This is when Hommer added its newer S33 with a B axis and automatic indexing. Today, Hommer’s O.D. grinding department consists of five STUDER machines: the first S40 purchased, a second S40, an S31, a basic S33 and the S33 with B axis. The department’s capacity is now about 350 hours per week and includes two shifts that complete over 2,000 unique details per year. In fact, 93 percent of Hommer’s jobs involve parts the company has never made before and most likely will never make again. “One advantage I have over someone just now entering the market for complex, custom parts is that I have invested in these machines over time and have the skilled labor to The O.D. grinding department consists of five STUDER machines – two S40s, one S31, a basic S33 and an S33 with B axis. Hommer produces cavity components, custom cores, rotating cores, custom core pins, thin wall ejector sleeves and complete stack-up tooling ranging from a .250" to 3" in diameter. Also known for its versatility, Hommer’s S40 machine offers a grinding length up to 63" and a fast direct drive of the infinite B-axis, a functionality that has opened the door to many new business opportunities for the shop. The STUDER grinders enabled Hommer to change its focus from manufacturing commodity parts to more complex parts that are larger in diameter, longer in length and achieve the precise tolerances customers need. The new capabilities coupled with an increase in communication with customers have helped Hommer triple its business and become a niche provider of cavity components, custom cores, rotating cores, custom core pins, thin-wall ejector sleeves and complete stack-up tooling. The shop creates the precision components out of all types of materials, including S7, H13, D2, M2, 420, copper and MoldMAX® , and most range from a quarter of an inch to three inches in diameter, although they have done some that are 12" to 13" in diameter. The bulk of Hommer’s pieces require an average of 15 operations, beginning with soft-state chipmaking operations, including cutoff, gundrilling, turning and milling. After the parts are heat treated, they hit the hard side of the house for centerless grinding, CNC O.D. grinding, CNC I.D. grinding, form grinding, surface grinding, honing, hard turning, hard milling, wire and sinker EDM, etc., all the way to final inspection. As business grew, the company added a new STUDER about every two years. “I initially selected the STUDER because the programming was superior,” explained Hommer, “and it’s the same across all machines. That’s a huge benefit to us because our lot sizes are small — averaging around 32 pieces — and our cycle times are short — around three to five minutes. We do about four changeovers per shift, and the simple setups and mechanical processes on the STUDERs allow us to set up in a half hour or less.”
  14. 14. Mitchell’s Life Field Service Manager Applies Improvement Processes at Work and in Life A G L I M P S E I N T O The Centerville Hustle, I decided to apply the same principles used in the PuLs project to help the other coaches and players improve. I record statistics during games — shots attempted and made, fouls, free throws, steals and rebounds — then use some of PuLs‘ data analysis tools which have revealed some interesting and actionable information. For example, the data clearly shows that our team is not a very good three point shooting team. It also shows where our “sweet spots” are for making high percentage shots. Presenting this information to the other coaches and the boys in an easy-to-understand manner has helped us better teach the boys how to make good shot choices, and the results have been good. The team has won most of its games and now sits at the top of the league standings. I look forward to continuing to learn and grow with UNITED GRINDING. Being a leader of a PuLs initiative has given me opportunities to make a difference for our company, our customers and a great group of boys learning how to play a great sport as a team. Outside of my work at UNITED GRINDING, I am an imaginative illustrator and sculptor and create one-of-a-kind sculptures out of colored telephone wire. My sculptures are of sports, science fiction, military, warrior and comic book characters. I also create commercial pieces. My art has been featured in museums and several art and craft shows across the United States. have always been fascinated by complexity in the world around me. Or maybe it’s more accurate to say that I have always been intrigued by the challenge of finding a way to simplify difficult or overwhelming things. So, when asked by executive management to spearhead a PuLs project that would help us improve across the company, I jumped at the opportunity. PuLs stands for precision and passion. It’s our philosophy and training program at UNITED GRINDING, and it is designed to improve processes and procedures throughout the company. It teaches us how to define and analyze problem areas and gives us good tools that take the emotion out of situations and force us to focus on the facts. Really, PuLs is so much more than a program; it defines our culture of always looking for better, more efficient ways of doing things. I have been leading a team charged with improving our customer order care process — one of six target areas we believe can have huge impact on our business. Our team identified several problems with our current process and worked through detailed statistical analysis to find the causes of the problems. Then, we developed new processes and procedures for correction that involve creating a new training program for our technical engineers and a budget for rolling it out. Learning these skills has given me a tremendous opportunity to really make a difference at UNITED GRINDING. They have also come in handy outside of work. As a volunteer assistant coach for my 10-year-old son’s basketball team, 24 Grind/Software & PM Issue 2015 Grind/Software & PM Issue 2015 25
  15. 15. eliable production is the primary goal of every metalworking operation. As a result, most shops choose grinding parameters aimed at guaranteeing that their processes will produce the desired part size, tolerances and surface finish time after time. Experienced shop owners and machine operators tend to apply conservative cutting conditions and stay with them. While the safest approach may seem like the best approach, it does not allow shops to take full advantage of the capabilities of advanced grinding machinery and tooling and thereby misses opportunities to maximize productivity, cost-efficiency and energy management. With typical on-machine grinding software packages, the operator enters information regarding the workpiece material, desired part dimensions, machine tool capabilities and tooling available. The software then determines appropriate feeds and speeds for a specific grinding cycle. The offline StuderGRIND software package provides a much more comprehensive approach. StuderGRIND provides workpiece-oriented programming as well as data collection, storage and analysis. With its StuderTechnology grinding support module, the software represents a powerful tool that minimizes grinding times and optimizes all aspects of the overall process. The software also compiles and analyzes cost and time data for use in documentation and creation of quotes. An optional selection of cycle-specific software modules provides the capability to perform and optimize processes such as dressing, contour grinding and threading. Because it operates offline from the grinding machine on an external PC, StuderGRIND delivers all of the above benefits while the grinding machine continues to produce parts. StuderTechnology The StuderTechnology module of StuderGRIND calculates process parameters, on the basis of the latest advances in grinding technology in combination with over a century of cylindrical grinding experience and know-how from Fritz Studer AG. The software considers approximately 300 machine factors and utilizes a database with integrated grinding knowledge that can be supplemented with data from a shop’s own experience. The software analyzes the most important process-relevant variables — such 26 Grind/Software & PM Issue 2015 Grind/Software & PM Issue 2015 27 StuderGRIND Software Optimizes, Documents, and Analyzes All Aspects of Grinding...Offline F E A T U R EF E A T U R E Tom Vieira, Application Manager, Cylindrical Division, United Grinding North America, Inc. Erhard Kämpf, Section Manager, Form and Thread, Fritz Studer AG
  16. 16. 28 Grind/Software & PM Issue 2015 Grind/Software & PM Issue 2015 29 as workpiece material and heat treatment/hardness as well as grinding wheel and cooling lubricant specifications — for each operational step. Data analysis includes automatic calculation of process parameters that essentially eliminates the need for further optimization efforts and can result in reductions of 25 to 50 percent in production time (see above sidebar). Beyond determining grinding feed and speed, the software analyzes and optimizes associated time-consuming activities including setup, programming and documentation. Virtual Machine Simulation STUDER pioneered “pictogramming” graphic language for use in programming the grinding process. Expanding that visual resource, StuderGRIND software permits the creation of an entire virtual machine that enables a user to work with images of the workpiece, grinding wheel and all components of the process such as dressing devices. The comprehensive visual overview facilitates the creation of setup plans and tool lists. Programs can be simulated and checked for collisions throughout the entire work envelope. The software calculates all process data individually and automatically for each operation and supplies a full graphic simulation. Use of the simulation significantly reduces the amount of time spent setting up and test running a grinding process. In addition to calculating machining time, the software determines total production time and data such as unit costs, enabling accurate calculation of job quotes. A Complete CAM System StuderTechnology is part of a complete CAM system that integrates optional expansion modules for dressing, form grinding and other specialized grinding applications. Implementation of the expansion modules can eliminate the need for special machines to complete specific operations. Users choose individual optional modules based on the Conventional Expertise and StuderTechnology Programmers and operators with extensive grinding experience can nearly always produce parts that exceed required specifications. However, the way to maximum productivity and profitability in manufacturing is to reliably produce, but not unnecessarily exceed, part requirements in the shortest amount of time. A comparison between a program based on expert knowledge and created conventionally and one generated by the StuderTechnology module of StuderGRIND illustrates the benefits of the module’s capabilities. The comparison test involved three operations of internal and external grinding on a flange. The required surface roughness was Ra 0.3 and specified roundness variation was less than 1 µm. Parts programmed, simulated and ground via the StuderTechnology module of StuderGRIND were consistently within tolerance and showed only minor variations in values. The same parts were also machined with a program created conventionally, based on expert experience. Surface roughness was consistently better than required, while roundness was better than specified for some parts and out of specification for others. Exceeding surface roughness requirements resulted in longer sparking out times that considerably lengthened the actual grinding time for the part. Actual grinding time for the StuderTechnology programmed operation was 26 percent faster than the time for the conventional program. The StuderTechnology programming time, on the other hand, was longer. Nevertheless, overall processing time (adding programming and grinding time) of the StuderTechnology programmed parts was shorter than that of the conventionally programmed parts. As part volume increased, the StuderTechnology overall time advantage grew. For one unit, the total time was 8 percent faster, growing to 22 percent with 10 units and 24 percent when grinding 100 units. The conventionally generated program was optimized to lower grinding times, bring surface roughness closer to specifications and produce consistent roundness. The optimization process process Parts programmed, simulated and ground via the StuderTechnology module of StuderGRIND were consistently within tolerance. consumed more than one hour of shop time. When that additional time is added to overall processing time, the StuderTechnology-generated program was 66 percent quicker than the conventional program when one unit is machined, 40 percent faster with a 10-unit run, and 26 percent faster when grinding 100 parts. The automatically generated StuderTechnology program immediately produced parts that met specifications in less time overall. No optimization was needed. And, the StuderTechnology software provided full documentation of the process parameters. CyClotron ProduCts, InC. Visit our website: Cyclotron Products, Inc. offers a complete line of filtration systems designed to remove solid particles from water soluble and synthetic industrial fluids using the most economical and efficient methods. Leaders in Filtration Systems CYC LONIC FILTRAT ION ENVIR ONMENTALLY RESPON SIBLE Economical Efficient • Extends coolant life. • Up to 30% longer grinding wheel life. • No purchase of replaceable filter media. • Low maintenance costs. • Small footprint. • More parts per dressing cycle. • Less machine downtime. • Eliminates amount of liquid waste. • Consistent coolant aeration eliminates bacteria problems. • Closer tolerances on critical parts. Enviromentally Responsible Cyclonic filtration benefits the environment as no disposable media is used in the process. This saves petroleum, preserves countless trees, and eliminates the associated environmental impact created by the disposal of spent filter media. Contact us to discuss all of your filtration needs. (262) 898-0710 • Fax (262) 898-0748 • 1509 Rapids Drive • Racine, WI 53404 parameters and variablesQuality Efficiency Optimized StuderTechnology Experienced Operator
  17. 17. Operation-Specific Expansion Modules for StuderGRIND software Implementation of the optional expansion modules for StuderGRIND often can eliminate the need to acquire special machines for specific operations. Choice of individual optional modules depends on the features and capabilities of the machine in use and the particular work a shop performs. StuderDress Because reprofiling a grinding wheel is time consuming and requires shutdown of part-producing operations, optimizing the dressing process provides a great opportunity for reducing overall production time. StuderDress offers an innovative strategy for the profiling of new wheels and the reprofiling of used wheels. The strategy incorporates an optimized number of cutting passes, including roughing cycles designed to eliminate unnecessary traverse movements and save time. Depending on the wheel profile, StuderDress enables a wheel to be dressed 3 to 10 times faster than with conventional methods. The module also permits setting of T-points at any location and angular positions on the tool to facilitate programming drawing. StuderContour Peel grinding is a highly efficient method for high-precision production of longitudinal contours. The StuderContour module of StuderGRIND employs peel grinding techniques to enable rotationally symmetrical shaft parts such as drills, taps and drawing tools to be roughed from solid. Wheel travel paths are chosen to result in the shortest passes possible and to maximize consistency of grinding wheel performance. A sophisticated correction function allows deflection, cylindricity and straightness to be ground quickly and accurately on parts with a critical diameter/length ratio in respect to dimension, form and position. The module features and capabilities of the machine in use and the specific work performed in the shop (see sidebar at left). StuderGRIND with StuderTechnology and optional expansion modules permits fast setups and quick adaptation to changing parts, offering value for companies that manufacture small lots or single parts. On the other hand, the software’s ability to store prior programs and incorporate ongoing changes makes it an excellent tool for high-volume shops when parts in production are subject to engineering changes. Non-production Time Savings Although many manufacturers concentrate nearly exclusively on reducing actual grinding time, reductions in time and effort spent on non-production activities such as programming, setup, optimization and documentation can have an equal or greater effect on productivity and profitability. StuderTechnology’s wide range of analytical tools determines where steps in the overall process can be modified and made more efficient. The benefits provided by StuderGRIND software combine to significantly reduce the total cost of ownership of the grinding system, ensuring that buyers achieve maximum return on their investment in a premium STUDER grinder. Automatic Quality and Speed STUDER compares the advantages provided by StuderGRIND software to those of modern photographic cameras. Where in the past extensive photographic knowledge and technical skill were required to maximize photographic quality and speed, today’s cameras feature software that seamlessly automates exposure, focus and image processing. A person with basic knowledge of camera operation can create top-quality photographs. Through its advanced software, STUDER aims to make processing of the majority of standard grinding applications equally as automatic and easy. And just as photographic automation is continually evolving and updated, STUDER modifies, improves and upgrades its grinding software to make it “future-proof.” With regard to larger global issues, StuderGRIND software possesses BluePlus features developed in recognition of the VDMA German mechanical engineering trade association’s Blue Competence initiatives to enhance manufacturing energy efficiency and sustainability. Companies that participate in the initiative’s policies are permitted to badge their machines with the Blue Competence logo. BluePlus represents STUDER’s effort to make its grinding systems more energy efficient and economical. Key to that effort is software that monitors 16 channels of machine operation and determines how to best utilize and conserve energy. Overall Grinding Support Offline StuderGRIND software combines a century of grinding machine and process development with present-day technology and manufacturing systems. Overall, the software and the STUDER cylindrical grinders it supports enable a shop to maximize its productivity, profitability and participation in environmental progress. Learn more 30 Grind/Software & PM Issue 2015 Grind/Software & PM Issue 2015 31 contains predefined step tool programs as well as full simulation capabilities. StuderPunch The StuderPunch module represents a highly automated and flexible solution for grinding of punches. Designed for individual components and small-batch production runs, StuderPunch is applicable on universal grinding machines and on production machines specially adapted for the process. A shop can store accumulated grinding knowledge in software memory for use in production jobs that will repeat at future times. Software-supported machining strategies provide highly efficient material removal and result in lower grinding tool costs due to reduced tool wear. The module is fully automated for streamlined production of families of die and press punch components. The software databank stores numerous die/punch cross sections and geometries in the DXF format. StuderThread StuderThread software expands the capabilities of a universal cylindrical grinder to give it the functionality of a thread grinding machine. Partial operations such as thread grinding can be carried out in-house, saving time and cost. The software provides immediate access to most common thread types. In addition, free-form thread profiles can be produced at any time, as can preset and other thread geometries. The software enables regrinding of pre-machined threads via an active probe for prepositioning the workpiece. Cylindrical diameters and threads can then be ground in a single clamping. StuderFormHSM and StuderForm Grinding of noncircular contours, forms and polygons presents a significant challenge for grinding machines, tooling and the personnel who program the processes. StuderFormHSM (High Speed Machining) is highly efficient software for out-of-round grinding that enables manufacturers to perform noncircular form grinding and meet customer demands for accurate production of complex contours. High path precision and simple operation in dynamic operations facilitate both individual component and large batch production. StuderFormHSM controls the axial drives directly and can thus handle highly dynamic process specifications. As an alternative, the StuderForm module is a simplified version of the software that expedites the grinding of cams and polygons in standard small-batch production. future proof Workpiece-oriented programming and data storage. Cycle specific visualization of the grinding tool in relation to the workpiece. StuderGRIND Grinding technology support software simulation, cost and time analysis. StuderTechnology Efficient profiling and reprofiling of grinding wheels. StuderDress Peel grinding with automatic definition of cutting passes, convex/concave grinding applications, contour grinding. StuderContour Highly automated and highly flexible solution for grinding of punches. StuderPunch Software for simple out-of-round applications. StuderForm This thread software turns a universal machine into a thread grinding machine. StuderThread Highly efficient software for out-of-round grinding, simple programming of forms and polygons. StuderFormHSM
  18. 18. 4. Cables are the Achilles’ heel of a metrology system. They’re routinely cut, pinched, abraded, attacked by chemicals and otherwise damaged. Synthetic coolants are a major cause of cable damage. If you use them, you need to increase the frequency of cable inspections. Maintenance alone won’t save your system. Good maintenance will extend the life of your metrology system, but it won’t make it last forever. You need to be aware that changing technology and increasingly strict environmental regulations are combining to make whole categories of spare parts scarce or even unobtainable. For example, the gas plasma displays that were state-of-the-art a few years ago are listed as environmental hazards today. They aren’t even available as like-for-like replacement parts. With the new RoHS standards, this trend is likely to escalate and will impact many components that are vital to older systems. Your maintenance records will indicate which components should be stockpiled while they’re still available, and which equipment you should consider replacing before the parts are discontinued. Good metrology systems aren’t cheap. A well-planned, regular maintenance program will maximize their life and help smooth the transition when it’s time to change. It’s never too soon to start. Learn more 32 Grind/Software & PM Issue 2015 Grind/Software & PM Issue 2015 33 Simple maintenance tips to keep running at peak efficiency. By Frank Powell, Product Manager, Grinder Products, Marposs Corporation F E A T U R E Common Sense Maintenance Optimizes Your Metrology Investment odern metrology hardware is incredibly durable and reliable, but it requires regular maintenance to get the maximum value from your investment. The program doesn’t have to be complicated; most of it is just common sense. Here are some simple tips to keep your metrology hardware running at peak efficiency. 1. READ THE MANUAL. This is capitalized because it’s seldom done. Every piece of metrology hardware comes from the manufacturer with a manual containing recommended maintenance procedures. Those procedures are based on the manufacturer’s experience with thousands of installations. Following them exactly will extend the life of your equipment and minimize your total cost of ownership. A routine preventive maintenance program can ensure that wide range in-process measuring heads such as the Unimar gauge maintain the accuracy typical of ultra high-performance comparators, even under the most severe operating conditions. The new generation P7up electronic amplifier for connecting to Marposs measuring heads and other devices represents an economical, practical and reliable solution for highly complex applications involving in-process workpiece monitoring on grinding machines. The unit has been designed as a direct, pin-to-pin replacement for previous generation amplifiers. 2. Clean Up Your Act. Precision equipment and dirt don’t mix. Modern gauges are tough and designed for the manufacturing environment, but dirt is relentless and the less of it a gauge has to deal with the longer it will last. If you READ THE MANUAL, you‘ll probably find a list of cleaning Do’s and Don’ts. They’re based on the manufacturer’s real-world experience and should be followed. Once gauges are clean, devote some attention to the filters on the electronics boxes. Hot electronics tend to die quickly, and a clogged filter on a heat exchanger is a sure way to speed up the process. Failing electronics can also produce erratic results that lead to scrap parts and, in extreme cases, mechanical damage. 3. Lubrication Is Not Optional. Not everything requires lubrication, but equipment that does won’t function for long without it. If you READ THE MANUAL, it will tell you what needs to be lubricated and the lubricant to use. Here again, the manufacturer’s recommendations are based on real-world applications and ought to be followed. In most cases, “Just as Good” probably isn’t. 4. Calibrate, Calibrate, Calibrate. Your gauges are subject to age, accident and operator error, as well as normal wear and tear. It’s unreasonable to expect them to perform well without periodic calibration. READ THE MANUAL to find out how to set up a calibration procedure and schedule. Then, follow it. Even the world’s best metrology systems aren’t worth much without proper calibration. The basic maintenance items outlined above should be tracked to ensure they‘re done regularly and provide insight into the impact of age on your system’s performance. Here are a few things to look for when you’re dealing with older hardware. 1. Inconsistent readings and calibration problems are often caused by worn contacts. Given enough time and cycles, even carbide or diamond will wear to the point at which the contacts must be replaced. 2. Dirt, coolants and other fluids are relentless and can infiltrate sealed components over time. You should schedule a detailed inspection of areas not subject to routine cleaning, especially if they’re sealed. 3. Threaded connections are subjected to normal vibration and thermal cycling and eventually will loosen and should be checked periodically. A loose fitting is also a pathway for contaminant infiltration. If a fitting is loose, you should detail check the attached devices.
  19. 19. 34 Grind/Software & PM Issue 2015 Grind/Software & PM Issue 2015 35 By Russ Waddell, MTConnect Product Manager, The Association For Manufacturing Technology hen it comes to manufacturing, smart energy use is just like many other cost-saving best practices. The easiest steps are usually obvious: don’t leave the lights on and HVAC running all night without a third shift on; cover up heated open tanks for processes, like chroming or anodizing; minimize the open door load/unload times for furnaces, etc. With modern sensors and computer controls, standards like MTConnect can give visibility to other energy choices that are not so obvious but can have major financial implications. The technology available for an energy-efficient factory of the future reaches across hardware, software and systems engineering. For machine tools, that means optimal component selection with subsystems like hydraulics, chillers and coolant, each chosen for the lowest possible energy consumption while maintaining high performance. Software comes into the picture to manage when each subsystem is active, and again when material removal processes are optimized at the CAM or CNC level. Process optimization on individual machines, with reduced scrap rates and lowered setup times, then feeds into a Manufacturing Execution System (MES) or Enterprise Resource Planning (ERP) System to cover an entire facility or multiple facilities. This top-to-bottom approach is the most effective way to manage energy consumption. Of course, most facilities don’t have the luxury of planning from the ground up with energy use in mind. Brand new machines installed into an existing system can save huge amounts of energy, but outdated or non-existent energy management tools and policies can make it difficult to actually identify these savings. Hidden energy savings will still help the bottom line when energy bills are lower at the end of the month, but better monitoring avoids leaving money on the table. In particular, local, state and federal energy savings grants and tax breaks can’t be fully taken advantage of without some additional detail and metrics on energy savings. MTConnect on new machines or as a retrofit serves up machine tool data in a format that is predictable, consistent and easy for modern computer systems to digest. For single machines or cells, proprietary data formats don’t create much difficulty. But as an energy strategy moves from one machine or cell to a full department, factory or multiple factories, translating data across brands or types of equipment gets expensive quickly. Because MTConnect data is standardized, the software options for collection, recording, storage, compilation and analysis extend beyond just industrial solutions. The manpower saved on both the shop floor and the back office from better software can be put to use spotting energy savings opportunities, productivity chokepoints and generally improving the bottom line. Higher level systemwide tasks are still better performed by a human, which means the same changes taken into consideration for the sake of energy savings also translate to better resource allocation across the factory floor. A systemwide view is important here because gains are relative. Like productivity gains, absolute energy savings from a machine almost always come from buying newer, better machines or components. With only older equipment in a shop, optimizing production between comparatively energy efficient and inefficient equipment can show big savings. That kind of optimization is already commonplace for maximizing capacity and delivery times; energy use is just another factor to consider. MTConnect makes it easier to get data off new or old machines, helping to identify the equipment and processes that are most energy intensive. With energy policies in place, new equipment can slot into place and increase the overall system efficiency. Manufacturers already have a huge head start in sensor, control and automation technology, and also have established options for energy management systems. As software options in both industry and consumer sectors expand, the expectations for interfaces, software, ease of use, capabilities and pricing will start to shift as industrial buyers continue to seek the best available options. The brightest future for energy savings, and indeed for productivity, comes when modern high-efficiency machine tools, MTConnect, and the best software available are combined. For now, it’s important to look at existing energy policies and how they relate to purchasing decisions. In many cases, there is not even a price premium for machine tool efficiency. MTConnect and other data connectivity features and options, whether new or retrofit, may also be important but underappreciated foundations for better energy visibility and efficiency. And lastly, there’s no reason not to set the bar high when it comes to energy. Advances in machine technology, interconnectivity and software mean the future of efficiency is looking bright. Learn more Standards-based Data Systems DriveEnergySavings MTConnect on new machines or as a retrofit serves up machine tool data in a format that is predictable, consistent and easy for modern computer systems to digest. MTConnect makes it easier to get data off new or old machines, helping to identify the equipment and processes that are most energy intensive. The brightest future for energy savings, and indeed for productivity, comes when modern high-efficiency machine tools, MTConnect and the best software available are combined.
  20. 20. 36 Grind/Software & PM Issue 2015 Grind/Software & PM Issue 2015 37 aunched in Kersey, Pennsylvania, in 1989, AcuTwist is the brainchild of owner Marcus Young. At the time, he was managing an internal machine shop at a specialty subcontractor that did a lot of production drilling in powder metal parts for automotive and outdoor equipment applications. Most of the holes were under 0.438" in diameter with depths typically five to 10 times diameter. The shop used carbide and high-speed steel drills and would go through about 100 drills per day, mostly because of poor drill performance. According to Young, finding drills that cut to size and held required tolerances was difficult, so the shop resharpened its own drills to size. However, the process lacked repeatability, which prompted Young to propose the purchase of a better resharpening system. The owners of the company were unwilling to make the investment. So Young took a leap of faith, secured a loan, acquired the equipment and opened AcuTwist for business in his garage with one manual tool grinder and a desire to succeed. The tiny shop was an almost immediate success, quickly picking up several customers after it became apparent that Young’s regrinding expertise resulted in drills with much longer life than standard tools. “I realized that by tweaking the geometry just a bit we could get longer tool life, cut rounder and straighter holes and reduce the size of burrs on the exits of through holes,” he explained. Business increased, and Young hired a couple of employees — including his now long-time shop supervisor Travis Papa — and purchased another manual grinder. All along, Young followed the evolution of CNC tool grinders and was well aware of their capabilities and how they could benefit his shop. So in 1998, Young made another significant leap of faith and purchased AcuTwist’s first CNC tool grinder — a WALTER HELITRONIC MINI POWER. He then acquired a WALTER HELITRONIC POWER grinder and eventually a second HELITRONIC POWER — all from United Grinding North America, Inc. — and moved the shop to its current location in Ridgway, Pennsylvania. WALTER tool grinders feature patented 3D gantry designs that provide the highest possible rigidity and precision. Their grinding spindles ride on massive cross slides within enclosed backwalls, while large C axes under their workheads allow complete grinding of highly complex tool geometries in single setups. This C-axis design also eliminates the need for rotary spindle axes and further enhances overall machine rigidity. GrindingSoftwareandOEMSupportHelpShopBattleBack F E A T U R E Proactive Planning Pays Off “Between our HELITRONICS, we run programs for more than 80 specialty tools and over 100 standard tool programs.” “As his TOOL STUDIO expertise grew, Young discovered that the software enabled him to produce unique geometries beyond those produced using PC-based programming.” With expertise in CNC tool grinders and TOOL STUDIO, Marcus Young created a business that was an immediate success.
  21. 21. AcuTwist kept growing, and Young continued to learn and capitalize on the capabilities of his first WALTER CNC tool grinder. The shop had expanded its offerings beyond that of just resharpening to include generating a wide variety of tool geometries such as step drills, drill/reamer combination tools, form tools and other specialty tools. To keep pace with increased demand, Young acquired the second WALTER HELITRONIC POWER CNC tool-grinding machine at this time. Because he had never produced a tool on a CNC grinder, Young — from the start — relied heavily on WALTER’s tool-grinding software when it came to generating tool geometries and developing machine programs. He progressed from the standard software to CyberGrind software and most recently to the advanced TOOL STUDIO grinding software. With TOOL STUDIO, Young gains programming flexibility combined with very simple operation via the program’s wizard, which walks users step-by-step through programming of even the most complex tool geometries. With minimal input of geometry data from users, the wizard function fills in the blanks from its database for rapid programming of drills, cutters, step tools, form tools and other rotary tools. As his TOOL STUDIO expertise grew, Young discovered that the software enabled him to produce unique geometries beyond those produced using PC-based programming. “With TOOL STUDIO, I can put two drill points together on the same tool,” said Young, “and use as many as six wheels to generate it. Between our HELITRONICS, we run programs for more than 80 specialty tools and over 100 standard tool programs.” That flexibility allows the company to develop multiple tool geometries tailored especially for machining of powder metal components — a tough job given the hard particles and other challenges that material presents. “In one application, we developed a drill/reamer for a Tier 1 automotive supplier that produces P/M parts,” Young said. “Now, we produce that tool in six different sizes for processing timing gears, transmission gears, bearing caps and other P/M drivetrain components. And, tolerances for these parts are often in the micron range.” According to Young, his shop actually got its start producing specials — a significant portion of its current business — when a customer in the tool and die industry needed a form tool to machine a helical electrode for its sinker EDM. “They didn’t even have a drawing and simply sent over the tool profile via a DXF file,” commented Young. “It was a small cutter with its largest diameter measuring only 0.125". But what made it a challenge was that we had to match more than 20 points on the profile, which we successfully accomplished with our WALTER grinders.” Now, AcuTwist produces all types of specialty tools, mainly from carbide blanks ranging in diameter from 0.157" to 0.875" with lengths up to 6". A tapered end mill with an angular tolerance of +/-0.05 degrees over a 1.500" length, for instance, is now nothing out of the ordinary for the small shop that started out resharpening drills. “With TOOL STUDIO, Young gains programming flexibility combined with very simple operation via the program’s wizard, which walks users step-by-step through programming of even the most complex tool geometries.” programmingflexibility unique geometries 38 Grind/Software & PM Issue 2015 Grind/Software & PM Issue 2015 39
  22. 22. rapidturnarounds Since then, AcuTwist has tried to go paperless whenever possible and employs multiple data backup strategies, including clouds and an external hard drive. The company also began purchasing tablets, which operators use on the shop floor to access prints and other job data. The information from these tablets is then uploaded into the WALTER grinders. An event like the flood might have deterred some shops, but it didn’t prevent AcuTwist from moving forward. According to Young, the company’s business model is a bit different than many larger tool-grinding companies, and he aims to keep it that way. “Our niche is rapid turnarounds on relatively small quantities of special tools — anywhere from one to 200 pieces. Plus, we often get projects with turnaround times of a couple of hours,” said Young. “And our HELITRONICS allow us to keep pace and continue to meet and exceed those customer needs.” Learn more Specialist for CNC rotary tables General importer for North America Rotec Tools Ltd. 5 Schuman Road, Millwood, NY 10546 Phone: (914) 941-7311 Fax: (914) 941-0226 Email: Wanted: local representatives New generation 500: • Modular design: 4 basic modules – over 170 variations • Up to 111 min-1 – clamp and release quickly – short cycle time • High degree of accuracy: concentricity, geometry and positioning • Compact and rigid construction – high spindle clamping torque • Fully impervious to IP67 as standard – IP68 optional (waterproof in bath) • Large workpiece clamp range • Competitive prices Rotec Tools Ltd. To increase output and boost unattended operations, AcuTwist’s HELITRONIC POWER grinders feature WALTER ECO Loader Plus and thermal compensation software that together allow the shop to run overnight in addition to the 10 to 12 hours the machines run during the day. The compensation software measures and adjusts for machine growth to ensure consistent grinding precision, while the ECO Loader Plus lets AcuTwist load over 80 tools. Mounted directly on the machines’ workheads, the ECO Loaders take up zero floor space. The combination of Young’s expertise and advanced CNC tool-grinding machine technology resulted in steady growth for AcuTwist, with the exception of the Great Recession of 2008 and 2009. But to say business has always progressed swimmingly might cause Young to disagree. In May 2014, AcuTwist suffered an unexpected blow when the nearby Clarion River overflowed its banks and flooded the shop. “Within hours everything was sitting in three feet of water, including our WALTER grinders,” recalled Young. “Adding to the deluge, the floodwaters mixed with several hundred gallons of stored synthetic grinding coolant, while machine motors and other vital components were completely submerged. Three of the five servomotors on each grinder were submerged, but amazingly, after we cleaned and dried them out, they were again fully operational.” According to Young, UNITED GRINDING technicians — through hours of over-the-phone support — helped the shop get its machines back up and running. The shop’s coolant supplier also stepped up to quickly deliver barrels of AcuTwist’s preferred coolant. “Even customers pitched in to help,” said Young. “One of our biggest customers called and wanted to know how they could assist us and offered space in their plant for one of our machines so we could continue to meet orders. The hard work from UNITED GRINDING, our suppliers and customers had AcuTwist operational again within three weeks after the flood and saved us a lot of aggravation and cost.” Only a few months removed from the disaster, Young is able to joke about it and take what lessons he can from the event. “One of the things the flood taught us is that grinders make good anchors,” he said. “But really, it taught us to back up files, programs, everything. I had backed up accounting information the night before, and it was stored on a thumb drive I had in my pocket. The drive got soaked, but that data was intact. But we lost a lot of blueprints, both from customers and ones we generated.” “One of the things the flood taught us is that grinders make good anchors,” he said. “But really, it taught us to back up files, programs, everything.” “Our HELITRONICS allow us to keep pace and continue to meet and exceed those customer needs.” 40 Grind/Software & PM Issue 2015 Grind/Software & PM Issue 2015 41
  23. 23. 42 Grind/Software & PM Issue 2015 Grind/Software & PM Issue 2015 43 Water-miscible fluids are high-technology products. These fluids require the addition of water and must be maintained on a regular basis to actively monitor the microbiological components. Water and mixing concentrate It all begins with properly filling the grinding machine with fluid. Grinding fluid emulsion is mainly comprised of water, and water quality (chloride content, hardness and pH) varies widely by region and country. Poor water quality can have negative effects on the coolant, machine parts and components. Chloride content should be as low as possible to avoid issues caused by corrosion. A mixing device can be used to achieve a finely dispersed, homogeneous emulsion. Mixing temperature (concentrate and water) of a minimum +50°F to a maximum +86°F is recommended. Properly filling the machine the first time makes future top offs much easier and encourages long fluid and sump life. Concentration monitoring Concentration is an important consideration when it comes to fluid life and should be kept within the recommended range. Therefore, it is important to consult your fluid supplier’s recommended optimal range prior to mixing. Maintaining the proper concentration range has significant impact on the overall performance of the emulsion. Too-high concentration will have a negative impact on the foaming behavior of the fluid, whereas too-low concentration will adversely affect performance and stability. Topping off Water evaporates over time, so it is important to top off fluids regularly to keep the sump in proper working order. Naturally occurring minerals in water do not evaporate; rather, they remain in the emulsion. As a result, to effectively manage emulsion hardness, it is best to use water that is de-mineralized or has been treated by reverse osmosis. pH value pH value indicates the microbiology condition of the coolant during use. As pH value decreases, chances for bacterial growth increase. If the pH value drops below the minimum limit, corrective measures should be taken, including involving a coolant consultant who can help restore proper values. ith proper use and a little maintenance, grinding fluid becomes a Liquid Tool that ensures maximum machine performance and improves surface finish and productivity. However, only fluid that is kept in tip-top condition at all times can deliver such benefits, and to get the longest working life out of that fluid, shops should take some simple preventive maintenance measures. Basically, fluids fall into two categories — neat oils and water-miscible cutting fluids. Each has a different composition, and therefore needs to be handled and maintained differently. Neat oils are very high quality oils, which go from the drum into the machine sump without the addition of water. As a result, filtration for neat oil products is essential. Good filtration helps keep the product clean and stable for quality grinding results. Neat oil products have the potential to remain stable over many years, which allows for increased return on investment. Rico Pollack, Head of Grinding Technology, Blaser Swisslube F E A T U R E A Little Grinding Fluid TLC Goes a Long Way Tramp oil filtration Efficient filtration and regular removal of the tramp oil with a skimmer are important steps to keep the fluid emulsion in optimal condition, which in the long run will help prolong sump life. When it comes to fluid, a little TLC goes a long way. Regular fluid maintenance promotes long sump life, which in turn reduces coolant disposal and eliminates the need to purchase expensive additives. About Blaser Blaser Swisslube develops and produces specialized grinding fluids for the metalworking industry to improve surface finish, enhance material removal rates, prolong wheel life and to fulfill other machine-specific demands. The company has broad experience in regards to usage and maintenance of coolants for more than 40 years. The company‘s in-house Technology Center at its headquarters in Hasle-Ruegsau, Switzerland enables Blaser specialists to test newly developed coolants and to recreate the versatile machining operations of its customers and partners in a realistic way. Blaser Swisslube’s goal is to help improve its customers’ grinding processes and thus to optimize their productivity and economic efficiency as well as surface quality. The right fluid, correctly used and monitored, becomes a Liquid Tool. Learn more
  24. 24. IntheZONEI N T H E Z O N E 44 Grind/Software & PM Issue 2015 Grind/Software & PM Issue 2015 45 HELITRONIC TOOL STUDIO CAD/CAM Software Facilitates Design, Programming, Simulation and Production of Tools and Production Parts The WALTER HELICHECK 3D non-contact CNC measuring machine employs a transmitted light camera and a laser sensor to scan and digitize cutting tools and production parts, creating 3D models that users can save, process, analyze and measure. The machine’s 3D Tool Analyzer software enables users to lay freely selectable planes at any position on the 3D model. The software then automatically analyzes the planes and provides exact measurements of tool parameters such as core diameter, rake angles and spiral pitch, even with variable lead. Working with the 3D model enables users to perform analyses offline at a separate station. Additionally, WALTER’s new 3D Matcher software allows users to overlay two 3D models within a graphical user interface and perform a color-coded comparison. Matching the models provides an instant evaluation of product quality and indicates deviations from desired values. WALTER HELITRONIC TOOL STUDIO CAD/CAM software makes possible fully automated CNC design and production of extremely complex geometries in one clamping on grinding machines from the HELITRONIC range. Integrated wizard technology incorporates the WALTER knowledge database to minimize the level of data entry required. Standard license versions offer nearly unlimited possibilities for tool geometry settings and provide pre-defined features and functionalities for specific tool styles. Service functions such as automatic warm up and opening of operations help maximize productivity. An advanced license option permits creation of user-defined tools as well as modification and adaptation of individual designs. The software ensures economic efficiency in batch sizes ranging from a single part to large-scale production. HELICHECK 3D Non-Contact CNC Measuring Machine Creates 3D Models for Analysis of Cutting Tools and Production Parts FEATURES AND BENEFITS • X-, Y-, Z-axis travels: 270 mm, 455 mm, 325 mm • A axis: 360 degrees • Length measuring capability E1 value: E1 = (1.8 + L/300) μm • Position resolution linear axes: 0.02 μm • Measurement value resolution: 0.25 μm • Maximum backlight diameter: 295 mm • Maximum laser diameter: 80 mm • Digitizes cutting tools and production parts quickly • Slider control permits free choice of cross-section slices • Performs runout compensation • No coding necessary for laser scan • Straightforward software requires no further programming • Software fully embedded in current software overlay (Easy Check) • Solid granite base offers high thermal stability and excellent damping properties • Width x depth x height: 1,117 mm x 1,390 mm x 2,012 mm FEATURES AND BENEFITS • User-controlled view permits focus on relevant data • Combine operations to produce tools of varying complexity • Click-and-edit enables immediate geometry modifications • 3D tool simulation featured throughout the entire design/creation process • Feedrate optimizer can produce time savings up to 30 percent • Automatic scaling allows simple resizing • Grinding time calculations include data for entire operation, individual steps and machine movement • Options facilitate production of step tools, burrs • Dressing and wheel shape options tailor wheel conditions to desired tool profiles • Tool and wheel data interface with WALTER measuring machines eliminates double data entry • Advanced tool measuring interface similar to an optical comparator • Compatible with Windows® XP and Windows 7 on PCs and laptops CAD/CAM software for fully automated CNC design and production on HELITRONIC machines. Provides 3D models using a transmitted light camera and laser sensor.